Independent Circulating Hydraulic Station Air-cooled Oil Cooler For Industrial

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Independent Circulating Hydraulic Station Air-cooled Oil Cooler

Independent Circulating Hydraulic Station Air-cooled Oil Cooler For Industrial

Independent circulation, precise temperature control: Equipped with its own independent motor and pump unit, it forms a closed-loop cooling circuit separate from the main unit's hydraulic system. This enables precise control and stable maintenance of oil temperature, unaffected by fluctuations in the main unit's operating conditions.
High-efficiency air-cooling, energy-saving and environmentally friendly: Utilizing large-sized axial flow fans and efficient finned heat exchangers, it cools the hydraulic oil through forced convection with ambient air. No cooling water is required, which saves water and has no restrictions on water resources, and the operating cost is low.
Strong cooling performance, stable and reliable: Designed for the high heat load of industrial hydraulic stations, the cooling power range is wide. It can effectively control the oil temperature within the optimal working range in high-temperature environments or continuous heavy-load conditions, ensuring the stability of the system.
Intelligent control, automatic operation: Integrated temperature controller, which can automatically start and stop the fan and circulation pump according to the set oil temperature, achieving fully automatic operation, energy-saving and efficient, and featuring protection functions such as over-temperature alarm.
Compact structure, flexible installation: Integrated design, small floor space, no need to connect complex water supply systems. Just connect the power supply and connect the inlet and outlet oil pipes. Installation is simple and convenient, suitable for mobile equipment or situations with limited space.
Easy to maintain and highly adaptable: No water channels prone to clogging. Daily maintenance only requires cleaning the heat dissipation fins; The air-cooling method makes it suitable for areas with water shortages, poor water quality, or low temperatures prone to freezing, with outstanding environmental adaptability.

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MDP Hydraulics

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Product Description

FAQ

Product Description

The independent circulating hydraulic station air-cooled oil cooler is a highly integrated, self-powered circulation unit-equipped forced air-cooling oil liquid cooling device. It is driven by an internal motor to pump oil from the main oil tank. The hot oil flows through an efficient finned radiator, and the large-power axial flow fan generates forced air flow to remove the heat. The cooled oil then returns to the main oil tank, forming an independent and closed-loop cooling circuit with the main hydraulic system. This product is specifically designed to address the overheating problem of industrial hydraulic systems and lubrication systems caused by continuous operation or high loads. Through precise temperature control, it ensures that the oil is always within the optimal working temperature range, thereby ensuring stable system operation, prolonging component lifespan, and reducing energy consumption. Its air-cooling design makes it particularly suitable for industrial settings with water shortages, poor water quality, mobile equipment, or limited installation space.

Working Principle

1. Oil suction and circulation:

The built-in circulating oil pump in the equipment draws the high-temperature oil from the bottom of the main oil tank (below the liquid surface) through the suction pipe.

2. Heat exchange:

The high-temperature oil is pumped into the flow channels of the aluminum plate-fin heat exchanger (the core heat dissipation component). The heat of the oil is transferred to the surface of the radiator through the excellent thermal conductivity of the aluminum fins.

3. Forced air cooling:

A large-sized axial flow fan driven by the motor generates strong forced air flow, which vertically passes through the dense fins of the radiator and quickly carries the heat on the fin surface to the environment, achieving efficient "oil-air" heat exchange.

4. Oil return and temperature control:

The cooled oil returns to the main oil tank through the return oil pipe to complete a cooling cycle. The system's integrated temperature sensors and intelligent temperature controller monitor the oil temperature in real time. When the oil temperature exceeds the set upper limit, the cooling system is automatically activated; when it is below the set lower limit, the system automatically stops, achieving fully automatic and energy-efficient operation.

3. Key Design Features and Advantages

1. Independent circulation, safe and reliable:

The independent pump unit and circuit completely avoid the direct damage to the radiator core caused by the pressure shock of the return oil pressure from the main system, improving the reliability and service life of the cooler. At the same time, it does not interfere with the normal working pressure and flow of the main system.

2. High-efficiency air cooling, energy-saving and environmentally friendly:

Using high-power fans and an optimized finned-type radiator, the heat exchange efficiency is high. No cooling water is required, completely avoiding the problems of scale formation, corrosion, leakage and cracking in the water cooling system, with low operating costs, no water resource consumption, environmentally friendly and strong adaptability.

3. Intelligent temperature control, automated operation:

Standard equipped with a PID temperature controller, users can freely set the start and stop temperature. The system automatically controls the start and stop of the fan and circulation pump according to the oil temperature, achieving unmanned operation, with significant energy-saving effect, and featuring an over-temperature alarm function.

4. Compact structure, flexible installation:

Integrated design, integrating the oil pump, motor, radiator, fan, and temperature control box into a sturdy frame. The structure is compact, with a small floor area. Just connect the power supply and the inlet and outlet oil pipes to start working. Installation is simple and quick, with low requirements for the site.

5. Multiple protections, sturdy and durable:

Motor protection: Standard equipped with IP55 protection level, with options for IP56 and IP65, dustproof and waterproof.
Explosion-proof option: It can be equipped with ExdII BT4/CT4 gas explosion-proof or ExdI Mb mine explosion-proof motors, meeting the usage requirements for hazardous environments such as those in the petroleum, chemical, and mining industries.
Excellent material: The radiator is made using the aluminum alloy vacuum brazing process. The surface of the fins can be treated with anti-corrosion coating; alternatively, a fully copper tube and copper fin radiator can be customized, which has even stronger corrosion resistance.

6. Strong functional scalability:

It can be integrated with filters in the circulation pipeline, continuously filtering and purifying the system oil during cooling, achieving both cooling and cleaning effects. It supports local control and remote signal control via PLC.5.

Product Outline Drawing:

Product Specifications:

Selection Guide

1. Calculate the required cooling power (heat dissipation):

Core formula: Required cooling power (KW) = Total heat generation of the system (KW)
The system's heat generation can be estimated by measuring the temperature rise of the oil: Heat generation ≈ Total power of the oil pump × (1 - Total efficiency) + Power loss from overflow valves, throttle valves, etc. More accurate calculations should take into account all heat-generating components.

It is generally recommended to choose a model with a cooling capacity slightly higher than the calculated value.

2. Determine the circulation flow rate:

The flow rate should ensure that the oil has sufficient time for heat exchange within the cooler. This is typically determined based on the effective volume of the oil tank and the desired cooling cycle. For example, it is required to circulate 4-6 times per hour.
The flow rate also needs to be matched with the flow resistance characteristics of the cooler.

3. Confirm operating conditions and environment:

Ambient temperature: The cooling capacity of the equipment is typically based on a specific ambient temperature (e.g. 35°C). If the ambient temperature is higher, a model with a greater cooling capacity should be selected.
Installation space: Measure the available space and select the model with the appropriate dimensions.
Power supply and explosion-proofing: Verify the on-site voltage and determine if an explosion-proof certification is required.
Compatibility of media: Verify the compatibility of the sealing materials of the equipment with the hydraulic oil, lubricating oil or gear oil used in the system.

Application Areas

• Hydraulic system: Cooling of hydraulic oil for equipment such as CNC machines, injection molding machines, presses, and hydraulic stations.

• Lubrication system: Cooling of lubricating oil for equipment such as reducers, gearboxes, and bearing housings.

• Engineering mining machinery: Hydraulic and lubrication system cooling for mobile or stationary equipment such as excavators, cranes, crushers, and shield machines.

• Energy and Heavy Industry: Cooling for wind turbine gearboxes, ship deck machinery, metallurgical rolling mills and other equipment.

• Special environments: Coal mines, petrochemical plants and other places that require explosion-proof equipment.

Installation, Usage and Maintenance Precautions

Installation:

The equipment should be installed in a well-ventilated area away from heat sources. Ensure that there is sufficient space for the fan's intake and exhaust ports (typically more than 1 meter in front and behind), and that the airflow is unobstructed.
The installation base should be flat and sturdy. If it is installed on a vibrating equipment, shock-absorbing pads must be added to the base.
The diameter of the oil suction pipe should not be smaller than that of the oil suction port of the cooler. It should also be as short and straight as possible (recommended to be less than 1.5 meters), with as few bends as possible to ensure smooth oil suction by the oil pump and to prevent suction failure and cavitation. The height of the oil suction (the vertical distance from the center of the oil pump to the liquid surface of the oil tank) should be less than 1 meter.
The temperature sensor probe must be submerged below the liquid level of the fuel tank.

2. Usage:

Before the first startup, it is necessary to ensure that the circulating oil pump is fully filled with oil. Oil can be added through the drain port.
Before powering on, check if the power voltage matches the required specification and ensure that the fan is rotating in the correct direction (the airflow should be directed towards the heat sink).
According to the system requirements, set the start and stop temperatures on the thermostat appropriately.

3. Maintenance:

Regular cleaning: Regularly use compressed air or low-pressure water to clean the fins of the radiator, removing dust, fluff, and other obstructions to ensure efficient heat dissipation.
Inspect the oil lines: Regularly check whether all oil pipe joints are leaking and whether the filters are clogged (if equipped).
Listen for abnormal sounds: During operation, pay attention to detecting any unusual vibrations or noises, which may indicate a problem with the fan bearings or the oil pump.
Long-term storage: If it is to be stored for a long time, the internal residual oil should be drained, and then cleaned and stored in a dry place.

FAQ

Product Foundation and Principles

Q1: What is the air-cooled oil cooler for the independent circulation hydraulic station? How is it different from a regular cooler?

A1: This is an independent cooling unit equipped with its own motor and circulation pump. It draws oil from the main oil tank, cools it, and then pumps it back to the oil tank, forming a closed loop isolated from the pressure of the main hydraulic system. The main difference lies in "independent circulation": it is not directly connected in series with the high-pressure return oil path of the main unit, avoiding damage to the radiator caused by system pressure shock. It operates more safely and reliably, and is installable flexibly, not limited by the main circuit.

Q2: Which is better, air cooling or water cooling? How should I make a choice?

A2: Both have their advantages. The choice depends on specific conditions:

• Air cooling: The advantage is that no cooling water is required, there is no water resource consumption, no scale formation, no risk of freezing and cracking, installation is simple, and the operating cost is low. It is suitable for areas with water shortages, poor water quality, mobile equipment, limited installation space, or environments with not extremely high temperatures.

• Water cooling: The advantage is that the heat exchange efficiency is usually higher and the cooling capacity is stronger. It is particularly suitable for fixed locations with high heat loads or in environments with high temperatures. The prerequisite is to have a stable and clean cooling water source and drainage system.

Simple judgment: If it's inconvenient for you to draw water on-site or you are concerned about the maintenance of the water system, air-cooled is a more reliable and cost-effective option.

Q3: What is the core working principle of it?

A3: Its operation is based on "oil-air" heat exchange. The built-in circulating pump draws the hot oil from the main engine oil tank and pumps it into the internal flow channels of the aluminum plate-fin type heat exchanger. At the same time, a high-power axial flow fan drives the ambient air to force its way through the dense fins of the heat exchanger. The heat of the oil is conducted through the fins to the surface and is quickly removed by the flowing air, thereby achieving the cooling of the oil. The entire process is automatically controlled by the temperature controller.

Selection and Configuration

Q4: How can I determine the cooling capacity of the equipment I need?

A4: The core of the selection process is to calculate the total heat generation of the system. A commonly used estimation method is: Required cooling power (KW) ≈ Total input power of the host system (KW) × (1 - System estimated efficiency) × Heat dissipation ratio. The system efficiency is usually taken as 0.7-0.8, and the heat dissipation ratio is taken as 0.3-0.5 (that is, it is expected that 30%-50% of the power will be converted into heat and dissipated by the cooler). To be on the safe side, it is recommended to choose a model with a cooling capacity 20%-30% higher than the calculated result. The most accurate method is to consult a professional engineer for thermal balance calculation.

Q5: How should the circulation flow rate be selected?

A5: The flow rate must ensure that the oil has sufficient cooling time. A rule of thumb is: circulation flow rate (L/min) ≥ effective volume of the oil tank (L) ÷ (6 ~ 10). This means that the oil can circulate 6 to 10 times per hour in the cooler. If the flow rate is too small, the cooling effect will be poor; if it is too large, it may cause the oil to stay in the cooler for too short a time, which also affects the heat exchange efficiency and will increase the power consumption of the pump.

Q6: What environmental temperature was the cooling capacity indicated on the equipment tested under?

A6: The rated cooling capacity indicated on the product sample is usually based on a standard environmental temperature, commonly 35°C. If the actual operating environment temperature of your equipment is higher than this value (such as in a hot summer workshop), the actual cooling capacity of the cooler will decrease. When selecting the model, it is necessary to consider the most adverse environmental temperature and may require choosing a larger model.

Q7: Can custom explosion-proof models be made?

A7: Yes. The standard products are usually of the non-explosion-proof type. For areas with explosive gas environments such as coal mines, petroleum, and chemical industries, explosion-proof models that comply with national standards must be selected. The electrical components such as motors and junction boxes are all of explosion-proof structure and have obtained the corresponding explosion-proof certificates (such as ExdII BT4).

Installation and Usage

Q8: Are there any special requirements for the installation location?

A8: The most crucial requirement is good ventilation.

1. Space: Ensure that there are no obstacles within at least 1 meter in front of the fan's intake and outlet of the cooler to ensure smooth air circulation. Do not install it in corners or enclosed spaces.

2. Environment: Try to install it in a cool and dust-free area, away from heat sources (such as boilers, furnaces) and exhaust vents.

3. Vibration: If installed on a vibrating equipment, shock-absorbing pads must be added to the base.

4. Oil connection: The suction pipe should be short and straight, with a diameter not less than the suction port of the equipment, and it must be ensured that the pump's suction height (the vertical distance from the pump center to the lowest liquid level of the oil tank) is less than 1 meter to prevent suction loss and cavitation.

Q9: What preparations are needed before the first startup?

A9:

1. Oil filling: Clean hydraulic oil must be filled into the circulating pump and the pipeline through the drain port on the cooler or by loosening the exhaust bolt of the pump, and all air must be expelled.

2. Steering check: Test the rotation directions of the fan motor and the oil pump motor by point operation (the fan should blow towards the radiator fins).

3. Temperature setting: According to the requirements of the hydraulic system, set the start and stop temperatures on the temperature controller reasonably (for example: set the start temperature at 35°C and the stop temperature at 30°C).

Q10: How does the thermostat work? How is it set?

A10: The thermostat detects the oil temperature through the temperature sensor inserted into the oil tank. When the oil temperature exceeds the set "start temperature", the fan and circulation pump will automatically turn on; when the oil temperature is lower than the set "stop temperature", the thermostat will automatically shut off. When setting, the "stop temperature" should be 3-10°C lower than the "start temperature" to prevent the equipment from frequently starting and stopping.

Maintenance and Troubleshooting

Q11: What needs to be done for daily maintenance?

A11:

1. Clean the radiator: Regularly (e.g. every quarter), use compressed air to blow from the inside out on the fins of the radiator to remove dust, fluff, oil stains, etc. This is the most important maintenance task to ensure the efficiency of heat dissipation.

2. Check the oil circuit: Check for any leaks at each connection point.

3. Listen to the operating sound: Pay attention to any abnormal vibrations or noises.

Q12: The cooling effect has deteriorated. What could be the reasons?

A12: Follow the steps below to troubleshoot:

1. Heat sink clogging: The fins are covered with dust and debris, which is the most common cause. Clean immediately.

2. Fan not rotating or with low speed: Check the power supply of the fan motor, capacitors (for single-phase motors), or bearings.

3. Insufficient circulation flow: Check if the oil suction filter is clogged, if the oil pump is worn out, or if the pipes are bent.

4. High ambient temperature: Improve the ventilation around the equipment.

5. Inappropriate or deteriorated oil viscosity: Check if the oil meets the requirements.

Q13: What should I do if the equipment noise suddenly increases?

A13:

1. Check if the fan blades are touching the protective net or there are any foreign objects.

2. Check if the bearings of the fan and oil pump are worn out or lacking oil.

3. Check if the base of the equipment is loose or if the shock absorber pads have failed.

4. Check if the oil pump is suctioning air (low oil level or air leakage in the suction pipe), which can cause cavitation noise.

Q14: What should be done if the circulating pump fails to pump oil or pumps a small amount of oil?

A14:

1. Ensure that the pump is fully filled with oil and all air has been expelled.

2. Check if the oil level in the tank is too low.

3. Check if there is any leakage or blockage in the suction pipeline.

4. Check if the rotation direction of the pump is correct.

5. If the pump is severely worn, it needs to be repaired or replaced.

Q15: How to use in cold regions during winter?

A15: In low-temperature environments, the viscosity of the oil will increase sharply, which may cause difficulties in starting or damage to the oil pump.

1. Select low-temperature hydraulic oil.

2. Set the low-temperature protection function on the thermostat (if available), and prohibit starting the cooling cycle when the oil temperature is below a certain value (such as 10°C). Only allow heating (if equipped with an electric heater).

3. For equipment without heating function, before starting the main unit, preheat the oil in the oil tank through other methods (such as auxiliary heating).